Research &

Empowering Lives

Our 60+ R&D engineers and international product experts focus on achieving product
leadership through innovation keeping consumer application in mind.

Crafted with consumer
application in mind

Maximum value
for money

Quality at
Design Stage

Best in class



Innovative Technologies


Advanced Grid Design

The high-quality grids are casted precisely with enhanced design by providing the mechanical strength to withstand the contraction and expansion during charge-discharge cycles to support longer life operations.

Unique Spine Design

High-efficient spines casted to maintain the stability and integrity of the battery plates. They are made in the way to anchor the active material by acting as a framework for contributing to the overall longevity and durability of the battery.

Pasting Process

An advanced and well-executed paste making process with precise thickness using high-quality trimming methodology for creation of a porous and conductive structure by ensuring the proper adhesion of the grid-paste interface.

Tube Filling Process

Efficient vibratory technique is used for filling the active material by making them adhere to the surface of the tubes enclosed, resulting in the precise packed density to undergo high frequent charge-discharge cycles.

Slurry Process

A novel design with pressurized filling methodology used to help the active material solidify and enhance their adherence to the external surface for smoothening the reversible chemical reactions resulting in the longer-life.

Separator Design

Segmented and permeable design of separators with enhanced porosity for ion-migration crucially made for preventing short-circuits. Introduced with thinner layer of cellulose for improved absorbent ability and degradation resistance in acid.

Gauntlet Design

Made with porous polymer material in a fixed range of porosity for efficient utilization of material. Provided with surface enhancements for uniform distribution of the active material to avoid shedding thereby contributing to the efficiency and longevity of the battery.

Charger Design

Provided with a user-friendly interface as a vibration resistant with high durability and reliability along with a complying standard in a region of operation. Included with a highly efficient compatibility alongside a compact and lightweight criterion easy for handling and storage.

Active Material

Enhanced surface area using oxide size formulations combined with rolled-up carbon sheets to overcome the sulfation rate thereby providing the increased conductivity for longer life-cycle at higher depth of discharge.

Research Initiatives

Carbon compatibility with lower water loss

Curing Improvements for higher utilization

Formation Program Design for reducing sulfation

Separator designs with increased porosity and higher life

Gauntlet design for leach-out reduction and better diffusion

Casting process design for corrosion reduction

Oxide formulations for better charge acceptance

Alloy content design considering unique characteristics

Polymer based active material projects

Electrolyte formulation projects

Cutting-edge Equipment


Microstructure Analyzer

We use DSX-1000 Microscope from OLYMPUS. We can do six different types of observation analysis with respect to the visual nature of the sample. The visible light is used for magnification to observe the microstructure of the materials which explains the details like grain boundaries, inclusions, and the overall morphology of the materials.

Grain Boundary Analysis

To study the interfaces between the metal alloys, grain boundary analysis is mandatory. The inter-metallic arrangements and crystallinity of the multiple metals in the alloys can be clearly studied for further enhancements to control the corrosion activity on the alloy structures.

Inclusion Analysis

The foreign particle presence in the lead alloys can have negative effects on mechanical properties, casting characteristics, and the overall performance of the alloy. They can also impact the alloy’s machinability and ductility. To control these impurities, inclusion analysis is done through optical microscopic analysis.

Pore Analysis in Gauntlets

As gauntlets act as an enclosed chamber for the positive plate, the possibility of material leaching is very high. To control this leaching, the pore size should be fixed in a range with respect to the thread thickness. The thickness measurements are in the micron range which will be easily measured through DSX-1000 with high precision and accuracy.


Particle Size Analyzer

We use PSA-1090 from ANTON-PAAR. They provide valuable information about the size and distribution of particles in a given material. This analysis uses laser light to measure the angular distribution of light scattered by particles. The intensity pattern provides information about the particle size distribution. Laser diffraction analyzers are versatile and can be used for a wide range of particle sizes. The particle size distribution range is narrowed down in Grey Oxide and Red Lead from various vendors to control the electrochemical behavior in our batteries.


X-Ray Diffractometer

We use D2-PHASER XRD from BRUKER. It is a powerful analytical technique used in materials science to study the crystallographic structure of a material. It provides information about the arrangement of atoms within a crystalline structure, including crystal phases, crystal orientation, and crystallite size. From the information received from XRD, material behavior can be predicted as the distribution of respective crystal phases results in the unique behavior of the battery performance and life cycle by controlling the product and process parameters.


Polishing and Etching

We use Semi-automatic polisher machine provided by CHENNAI METCO. To create a smooth and flat surface on the material, polishing process is done to make it suitable for microscopic examination. This is done by the polisher machine that applies pressure and motion to the material against a rotating polishing cloth or wheel. It is necessary as the polished surface allows for better optical clarity and is essential for obtaining high-quality microscopic images. After polishing, the material is exposed to a chemical etchant. The etchant reacts preferentially with certain microstructural features, making them visible under a microscope. Etching highlights features like grain boundaries, phase boundaries, and other microstructural details, making them easily distinguishable.

Patents Filed

44 Design Patents

5 Process Patents

7 Product Patents

Innovative Technologies


Unity Power Factor

Incorporating Efficient Transformer Design that has optimised flux density and a high-density aluminium conductor, Efficient and Powerful Circuit that uses high current density switches with lowest gate charge and a robust Temperature Compensation mechanism that is designed to handle 2.25 times the rated capacity, Unity Power Factor at bulb load is achieved.

360-degree changeover synchronisation

Using the highly accurate Failure Angle Measurement Technology that measures the grid failure point by dividing its waveform into 360 points and stores the data to start the waveform from the very same point to keep the DC component being produced under 5% and Residual Energy Measurement Technique that equates the distribution angle by measuring the residual shift of hysteresis curve as soon as the grid power fails, an almost perfectly synchronized changeover is promised to protect the equipment running on it from the DC component.

Fuzzy logic control-based input power factor correction

Using the Advanced FLC Algorithm Technique that employs software based FLC logic to synchronize the charging pulses in sinusoidal pattern with highest duty at 00angle and lowest duty at 900angle to fetch the maximum power when the waveform is at lower degrees, Measuring the Frequency Shift, Measuring the Shift Error and with the Fastest Pulse Correction (66 microseconds), the technology ensures near to unity power factor while charging with reduced electricity losses. This is a first of its kind PCU in India.

Battery Less/Free Pickup

Inbuilt Deep Discharge Protection that can revive the power backup system event at zero volt. As soon as the grid is connected, a NC switch supplies the power to the power transformer. A DC supply is then generated using an H-Bridge topology and is used to charge the batteries, including those with zero or low voltage.

Crest Factor 3.3:1

A higher crest factor indicates that the system can handle significant short term power spikes effectively. The Continuous Peak Handling Technique ensures that devices within the power circuitry are rated for continuous operation at levels equivalent to their peak handling capabilities, thus facilitating the attainment of a high crest factor. In parallel, the Module-by-Module Loss Reduction approach is employed to achieve the industry's peak crest factor by systematically minimizing losses across all components involved in delivering backup power, spanning from the DC wiring to the switching devices and static transfer devices. This optimization results in the ability to accommodate peak currents reaching 330% of the rated current at the specified voltage levels, achieved by minimizing wire DC resistance (DCR) to its operational limit, as well as reducing switching and conduction losses of the devices to their peak current capacity, and simultaneously mitigating DCR and reactance in static transfer devices to handle peak currents. The combined result is a rapid rate of current change (dI/dt) across the entire product, yielding a remarkable crest factor of 3.3 times, thereby confirming the product's capacity to effectively deliver genuine power.

GPM Technique

The gravity profile management technique serves the purpose of reviving deeply discharged batteries suffering from hard sulfation, preserving the capacity of aging batteries, and ensuring that batteries are charged to their optimal charge acceptance level. This approach employs multiple strategies, including Continuous Monitoring of Battery Voltage for foldback, whereby an internal algorithm stores foldback points to prevent energy losses and overheating, automatically adjusting the gravity profile to sustain the battery. Additionally, it Continuously Measures Charging Current, reducing it to the charge acceptance level when necessary to avoid excessive losses. Furthermore, a Pulse Current Technique is employed to counteract hard sulfation caused by low electrolyte levels, with intermittent current pulses used to revive the battery and mitigate the adverse effects of sulfation. These combined techniques help maintain battery performance across various environmental conditions and battery ages while preserving charge acceptance levels.

Auto Revival from Over Temperature

It restores power promptly once the internal system temperature falls within desired limits, employing a temperature guard algorithm that continuously monitors critical component temperatures; if they exceed specified limits, the system safely shuts down, records conditions, and resumes from the same point upon restoration.

ECAC Technique

Improved THD among its peers even at heavy inductive loads: Error check analogue compare technique is being used to improve the THD (Total Harmonic Distortion) of the output waveform. In this technique, a closed loop feedback algorithm is being used.

Highest MPPT efficiency

Reaching an impressive efficiency of up to 98%, a remarkable 6.6% higher than competitors, is attributed to a two-fold approach. First, a unique technique in the buck converter effectively minimizes power loss related to the DC side input diode. Second, the buck converter is designed to operate at a frequency four times higher than that of competitors, significantly reducing the size of magnetic components, ultimately leading to enhanced system efficiency.

Research Initiatives

IOT enabled systems


Real Time, line Synchronization

In a “Wink” changeover

DC Cascade Inverters

Increasing the power density

Next generation AVRs

High Frequency online UPS

CAN based EV charger

Project UltraVolt: Redefining High Power at Low DC Bus

Cutting-edge Equipment


High End Solar Array Simulators up to 15kW (Make: Chroma, Model Number: 62150H-1000S)

These simulators accurately replicate the electrical output of solar arrays with a power capacity of up to 15kW. In R&D, they allow us to test and optimize the performance of power electronics systems under various solar conditions. This includes assessing the efficiency and reliability of inverters and converters when connected to solar panels, as well as ensuring compatibility with different solar technologies.


Programmable AC Source up to 12kW (Make: Chroma, Model Number: 61812 12kva)

Programmable AC sources generate controlled AC power. In R&D, they are used to simulate various grid conditions and voltages, enabling the testing of power electronics equipment's response to grid fluctuations. This helps ensure that the company's products can handle different grid scenarios and maintain stability.


200Mhz, 4 channel with isolated probes Oscilloscopes (Make: Yokogawa, Model Number: DLM 3024 . 2.5 G/s – 2000 mhz)

High-frequency oscilloscopes are crucial for analyzing and visualizing electrical waveforms. In Power Electronics R&D, they are used to troubleshoot, analyze, and optimize electronic circuits, especially in high-frequency applications. The ability to observe fast-switching waveforms and signals is vital for developing and fine-tuning power electronic systems.


3 Phase Power Analyser (Make: Yokogawa, Model Number: WT310EH)

This instrument is used to measure and analyse the electrical characteristics of three-phase power systems. In Power Electronics R&D, it is used to assess the performance of power converters, measure power quality, and analyse the efficiency of three-phase systems. It ensures that our products meet performance standards in real-world applications.


True Sine multimeters cum data logger (Make: Fluke, Model Number: 287 true RMS)

These multimeters provide accurate measurements of voltage, current, and other electrical parameters. In Power Electronics R&D, they are used for diagnostics, troubleshooting, and quality control. Additionally, the data logging feature allows for continuous monitoring and recording of electrical data, which is essential for tracking the performance of power electronics systems over time.

Innovative Technologies


App Monitoring

Our Lithium-Ion batteries are equipped with a monitoring app that provides real-time updates on battery status, such as remaining charge, any active protection mechanisms, as well as the ability to remotely lock and unlock the battery, among other features.

Cell Characterization

Considering different criteria as modeling perspectives (electrical model, electrochemical model, thermal model, mechanical model, or combinations as electro-chemical models), used equipment (Source–load, climatic test chamber, shaker, etc.), levels (material level, cell level, pack level, system level), methods (sequence of pulses, electrochemical impedance spectroscopy), time scale of the models or characterization standards.

Robust Battery Designs

The robust, high-quality structures of our battery packs ensure their resilience even in the harshest road conditions, leading to an extended lifespan. Following exposure to severe custom vibrations, drops, and shocks, our batteries experienced only a 3.5% degradation in actual capacity, whereas competitor batteries exhibited a 6-7% decline.

Battery System Evaluation

Our energy storage research team conducts a series of tests on commercially available batteries, ranging from the cell to pack level. These tests include aging, thermal, abuse, and vibration testing. Additionally, the team routinely disassembles battery packs to identify failure mechanisms that must be addressed in our battery pack designs.

Simulation and Modelling

Our validated suite of models enables the prediction of battery performance across a broad spectrum of conditions and applications. These models span from high-level 1st order models to equivalent electrical circuits and thermal models, all the way to electrochemical models. They are designed for use at the vehicle level down to the component level, providing insights into fundamental electrochemical phenomena affecting aging.

Test Techniques Development

Our engineers are experienced in the test and characterization of battery cells, modules and full battery packs and we are using our experience to develop next generation test strategies. While our primary focus is on vehicle propulsion applications, we are equipped to handle battery testing for other sectors including static power storage, consumer goods and more.

Thermal Characterization

Understanding the thermal behavior of a cell, module, and the complete vehicle battery pack under various operating conditions, including real-world drive cycles, is crucial for the design and development of successful cooling systems. Our capabilities extend from the thermal characterization of a single cell to the evaluation and optimization of different cooling technologies for vehicle packs.

Thermal Cycling

Cycling through two temperature extremes, typically at relatively high rates of change. It is an environmental stress test used in evaluating product reliability as well as in manufacturing to catch early-term, latent defects by inducing failure through thermal fatigue.

Mechanical Analysis

Mechanical Analysis enables us to solve complex structural engineering problems and make better, faster design decisions. With the finite element analysis (FEA) solvers available in the suite, solutions are customized and automated for structural mechanics problems, and parameters are set to analyze multiple design scenarios.

Cutting-edge Equipment


Ageing Tester

Used to perform ageing cycles and performance testing of battery packs.

Driving Cycle Simulations

By uploading the test graph or catalogs of a powertrain, a vehicle level performance tests can be performed with the continual monitoring the status of cell’s (Voltages, Delta V and time)


During the ageing cycle, energy can be regenerated, and the regeneration efficiency is greater than 85%. Which is much higher than ordinary ageing testers.


Thermal Chamber

Used to perform the durability test of the battery pack at different temperature limits (0°C, 25°C, 45°C) and different thermal cycles (0-25-45-55°C).